KHONAINI PETROLEUM SERVICES

K. P. S
METHOD STATEMENT CONCRETE WORKS
RAZ AL KHAIR ALUMINUM SMELTER
CONSTRUCTION OF FUEL AND LUBRICATION STATION
Project Doc. No: Re. No: P!"e
Table of Contents
1. Scope
2. Purpose
#. References
4. Responsibilities
5. Equipments
6. Material
7. Sop !ra"in#s
$. Proce%ure
$.1 E&ca'ation an% (ac)fillin#
$.2 *orm"or)
$.+ Steel Reinforcement
$.4 Embe%%e% Metals, -ncor bolts
$.5 Concrete Placement . Sta#e/10
$.6 Concrete Placement . Sta#e/20
1. Concrete Compaction
1.1 Curin# of Concrete
1.2 Curin# of Top Surface
1.+ Curin# of 2ertical Surface
1.4 Curin# Compoun%s
1.5 Pre/ Cast Concrete
1.6 Pre Concrete Placement -cti'it3
1.7 -cti'ities %urin# te Concrete Pourin#
$.% Release of *orm"or)s
$.$ Repairs
KHONAINI PETROLEUM SERVICES
K. P. S
METHOD STATEMENT CONCRETE WORKS
RAZ AL KHAIR ALUMINUM SMELTER
CONSTRUCTION OF FUEL AND LUBRICATION STATION
Project Doc. No: Re. No: P!"e
1.14 5ater Proofin#
1.11 Coatin# an% (ac)fillin#
14. Safet3
11. -ttacment
KHONAINI PETROLEUM SERVICES
K. P. S
METHOD STATEMENT CONCRETE WORKS
RAZ AL KHAIR ALUMINUM SMELTER
CONSTRUCTION OF FUEL AND LUBRICATION STATION
Project Doc. No: Re. No: P!"e
1. SC6PE
The scope of this method of statement is to cover concrete works activity which includes
( Formworks installation, rebars supply and installation, concrete supply and placement, water
proofing, etc.) d supply for cast in situ Concrete in the project. n accordance with contract
re!uirements and approved project specification, project safety procedure and approved issued for
construction drawings.
2. P7RP6SE
The method statement shall address the precedence of physical operations applicable for the
supply and placing "tructural # nonstructural Concrete on the project.

This $ethod "tatement is to ensure that concrete works activity will be e%pedite in an efficient
and safe manner in accordance with all relevant contract documents, ("pecification and
&rawing) and international accepted methods, utili'ing proven methods and procedures, as
detailed herein and was implemented on previous projects.
This $ethod "tatement is for submittal to Consultant # (mployer for their concurrence.
This $ethod "tatement will, if deemed necessary, be revised as and when re!uired to
accommodate circumstantial re!uirements that cannot be foreseen at this page.
+. RE*ERE8CES
!& )roject "tandard "pecification for C*+C,(T( -*,.
/0102 3 4444 3 5)" 3 &644 3 4447 ,ev. 447 for Concrete -ork
/0102 8 4444 3 5)" 8 &647 3 4447 Furnishing and &elivering ,eady8 $i% Concrete
/0102 8 4444 8 5)" 3 &947 3 4447 ,einforced steel, (mbedded items and
$iscellaneous Concrete :ccessories.

'& (+ /4;87 Concrete specification, performance, production and conformity.
c) (+ 7/;/4 3:ggregates for Concrete
KHONAINI PETROLEUM SERVICES
K. P. S
METHOD STATEMENT E(CAVATION
RAZ AL KHAIR ALUMINUM SMELTER
CONSTRUCTION OF FUEL AND LUBRICATION STATION
Project Doc. No: Re. No: P!"e
d) (+< 75;24 (%ecution of Concrete "tructures
e) :C 512 9uide to Formwork for Concrete
f) :C 540.7 "pecification for =ot -eather Concreting

4. RESP68S9(9:9T9ES;
)roject &irector # )roject $anager have the responsibilities for overall the project
activities including safety measures.
)roject (ngineer # Construction $anager (Civil)> n charge shall be responsible for
coordination and supervision of construction works (activities) and construction groups,
ensuring that works is done as per project specification and approved drawings, and
all safety measures are implemented, of site construction and report to construction
manager civil.
"ite (ngineer # "ite 9eneral Foreman> "hall be supervising closely that activities
designated to them ensuring that all instruction are followed are strictly adhered to,
(this may involve providing alternative access routes for moving Traffic with Traffic
"igns if necessary are in place prior to commencing the work, safety procedures of the
project are strictly followed.
The "( shall be responsible for the following>
To ensure construction is carried out to the re!uired )roject "pecifications and
drawing as well as in accordance with the approved T)?s and @C)?s and to this
method statement.
To ensure that the surveyor has completed setting out with reference points complying
with the approved for construction drawings.
(nsure that all parties who are re!uired to make any kind of test # inspection are
suitably informed as to the overall program of the works and daily inspection testing
re!uirements.
(nsure checking and performing the concreting as per the "pecification.
The @C (ngineer or his designee (@C) shall be responsible for the following>
,eview all relevant documentation and test reports issued by parties involved ("(, Aab
Tech (TA Aaboratory), "urveyor and @C nspectors) and submit records to consultant.
(nsure that all discipline activities that re!uire to be inspected in the concreting
operation has been inspected and approved.
*rgani'ed and allocate inspection works to the @uality Control nspectors (Civil).
To issue +C,?s # &,?s, when and where re!uired and to check that the construction
department provides timely appropriate corrective and preventive action.
The @C shall be responsible for>
"ign off and obtain signatures from the Consultant on the forms and verifying
documents as re!uired.
:ccompany the Consultant "upervision representative if re!uired, to carry out
inspections and release of hold points
dentifying and reporting to the @:#@C $gr. any non8conformances
.eeping a daily log of all the inspection ,e!uest submitted by the "(.
Carry out statistical analysis of the inspection and test result to improve !uality control
operation on site, to verify testing compliance and to advise the "( of the results.
Filling and compiling controlled copies of all test reports under the supervision and
instructions of the @C (ngineer.
The Aab Tech shall be responsible for>
"ampling and conducting field testing according to the instruction of the consultant and
@C $anager and in accordance with the "pecifications.
The TA ( ndependent Testing Aaboratory ) to ensure that the re!uired numbers of
samples are taken from concrete works for the evaluation of !uality and &urability of
Concrete works.
The Aaboratory technician # (ngineer shall be responsible to test all concrete
aggregates constituent for !uality ensuring it complies with specifications re!uirements
and abide with the pre!uency stipulated in the specification.
(nsure that all tests re!uired specified for frsh concrete )roduction is completed.
ssuing, reviewing # interpreting all laboratory test result report in timely manner,
submitting it to @C department keeping records in laboratory for consultant ,eference.
Compilation and filling all laboratory Test Forms # ,F for Certification submitting all
records to @C department.
"caffolding "upervisor> To ensure that all scaffolding system has been erected
accordingly to safety and re!uirements.
"afety nspector> To ensure all safety precautions has been taken into consideration
before commencing the concrete works.
:ll e!uipment should be inspected by 6echtel inspector and should have entry pass
before working on site.
:ll heavy e!uipment operators such as e%cavators cranes, forklift, etc, should have
third party license.
). E<79PME8TS;
0.7 Concrete $i%ing and Transport e!uipment
0./ ,eady $i% Concrete 6atching )lant
0.5 Transport $i%er
0.1 Concrete )ump

0.0 =oses # Concrete shoots

0.; Concrete buckets

0.2 :ir Compressor
0.B "urvey (!uipment
0.C Aevel
0.74 Total "tation ( "urveying instrument for checking the levels D distances )
0.77 $asonry :ccessories
0.7/ -heel 6arrows
0.75 Concrete <ibrators
6. M-TER9-:;
;.7 Form )lywood
;./ Timber
;.5 "caffolding
7. S=6P !R-598>S.
a. :pproved # ssued for Construction &rawings
$. PR6CE!7RE
$.1 E&ca'ation an% (ac)fillin#?
:ll the areas where e%cavation is re!uired, the surveyor will give the information to
the e%cavation foreman to start the e%cavation to the levels indicated in the ifc
drawings.
:fter the e%cavation is completed, the surveyor will check the final grade of the
e%cavation and the grade will be adjusted accordingly.
Compaction shall be completed and shall be tested by an inspection company
( ndependent third )arty laboratory ).
"light trimming will be carried out when and where re!uired before the placing of
polyethylene plastic sheet.
Concrete blinding will be carried out where indicated in FC &rawings.
)olythylene plastic thickness to comply with the project specifications.
Cast in situ elements shall be constructed in accordance with FC drawings and line
with project specification.
$() and Civil insert will be in place.
"urveyor shall mark the location of structural member ( foundation, wall, Column,
etc.) as per approved drawings.
(%cavation shall be carried out up to bottom level of blinding, leveled, sprayed with
water, compacted and tested as per relevant specification and approved drawings.
(rect formwork for blinding with concrete mi% class C7/#70.
:llow the concrete blinding to be hardened and cured as per relevant specification.
:pply approved protective coating # &amp proofing or water proofing membrane on
top of blinding as per specification and approved drawings.
n specific condition and coordination with consultant when concrete workability is
not meeting prevailing placement condition, re tempering of concrete with admi%ture
shall be carried out.
*n specific areas where rate of concrete placement is to be very slow &ry mi%
concrete will be delivered to site. -ater and Concrete admi%ture meeting concrete
mi% design re!uirements will be mi%ed on small batches using small site $i%ers, the
same site mi%ers will be used for Cement plaster.
-here construction joints detailed on the drawing, width of concrete element warrant
establishment of construction # e%pansion joints, or concrete placement to be
stopped due to an avoidable circumstances on site, Construction joints shall be
made, Concrete surfaces will be roughened cleaned to establish a good joint
between old and new fresh concrete, @C inspection, Consultant approval is re!uired
before concrete placement continue in concrete member.
*n water retaining Concrete "tructure and detailed on issued for Construction
&rawings, approved water stops will be used as re!uired by the project
specifications.
*n concrete slabs and where detailed on drawing, (%pansion # Construction joints
will be established, the joint will be sealed with approved fle%ible materials.
Cleaning of "tarter 6ars shall be carried out following concrete placement completed
in preparation for the ne%t concrete pouring.
$.2 *orm"or)
Concrete placement will not commence before (ngineer :pproval of Formwork and
,ebar nstallation.
The design and construction of formwork shall take account of safety and of the
surface finish re!uired. The formwork will be sufficiently rigid and tight to prevent loss
of grout or mortar from the fresh concrete and stand concrete <ibration ((%creted
=ydrostatic )ressure) without $ovements. Form work and its supports to maintain
the correct position and to maintain correct shape and profile.
The formwork for foundation, beam connection, column neck and manholes etc. will
be made of either traditional formwork (plywood and timber and supported by tie rod
and steel support ) or &*.: system which a combination of &*.: wooden beams,
plywood and &*.: steel supports system with tie rod.
$olds and formwork shall be prepared according to the FC drawing.
Formwork will be placed and aligned fi%ed to the re!uired dimensions as detailed in
issued for construction drawings by the carpentry crew.
Formwork shall be rigid # sturdy and fi%ed in such a way to retain the structure
members dimensions.
@C nspector will check the formwork installation and safety officer to ensure safety
of the work.
6efore placing the steel reinforcement, an approved form release agent will be
applied to the internal face of the formwork.
For columns, walls shutter will not be closed before @C and consultant releases.
$.+ Steel Reinforcement;
9rade of "teel will be as follows>
60446 for /4mm and larger diameter
6044C for 7;mm and smaller diameter
6ased on the issued bar bending schedule, steel cutting and bending will be carried
out either in site fabrication shop # supplier fabrication work shop delivered to site
and assembled on site as per approved FC drawings.
,einforcement will be placed above ground not in touch of soil, either using wooden
blanks or concrete base to comply with project specification and international
accepted procedures.
Epon the arrival of steel rebar to site fabrication shop, the rebar fabrication crew will
cut and bend rebar in accordance with project specification and FC drawings.
The rebar will be transferred to site by pick up or trailer and tagged.
6efore placing the fabricated rebar inside the formwork or mold, the formwork shall
be clean, blown out by air with air compressorvand coated with approved releasing
agent.
,ebar will be placed according to the project specifications and FC drawings.
,ebar will be assembled either inside or outside the concrete member, outside
assembly steel will be placed by a crane to avoid any disturbance to the water
proofing materials # or polyethylene plastic sheet. :dditionally, when leveling
concrete is provided, rebar mats can be assembled in the place.
,einforcement support shall be properly assembled at site> non metallic or plastic
concrete spacer shall be used to maintain the cover as re!uired by the
specifications.
$.4 Embe%%e% Metals, -ncor bolts;

:ll embedded materials items for civil. $echanical or electrical activities shall be
placed # inspected by @C inspectors ensuring materials comply with specifications.
:ll embedded items shall be unpainted unless noted otherwise, and free of
deleterious materials, such as dirt, grease, and heavy scale.
:nchor bolts and other embedded items shall be positioned and secured within the
tolerances shown on the drawings, in accordance with (+< 75;24 and as re!uired by this
specification.
:ll embedded elements to comply with the project specification and fabricated in
accordance with FC drawings.
The embedded metals and anchor bolts will be installed in accordance with FC
drawings.
The @C inspector shall check formwork, rebar steel, embedded metal and anchor
bolts prior to concrete placement.
"ection # "ite (ngineer will submit ,e!uest for inspection to @C inspector prior to
start site delivery of concrete.
:fter the concrete has hardened sufficiently, the e%posed portion of anchor bolt shall
be cleaned of all concrete and the threads chased. Threads shall then be carefully coated
with grease and the washers and nuts installed.
$.5 Concrete Placement;
Sta#e 1;
)roject (ngineer # "ection (ngineer shall ensure Concrete 9rade # Class is
approved by consultant # clients, the following concrete grades shall be used>
o :ll cast in place concrete 888888888888C54#52
o )recast $embers8888888888888888888888C14#04
o 6linding concrete88888888888888888888888C7/#70
o $isc. Concrete88888888888888888888888888C/4#/0
The @C inspector ensures that mi% &esign )roportions # 6atch weight available in
batching plant.
,eady mi% concrete supplier is aware of project specification re!uirements for
concrete temperature and slump.
Formwork installed to true lines and levels.
,einforcement as per approved drawings and bar bending.
(mbedded elements, inserts, bo% outs chases, chamfers, water bars etc. as per
approved drawings.
"urveyor marks the concrete top level on the shutter as per approved drawings.
Formworks is clean from inside using compressor and magnetic bars used to remove
pieces of binding wires.
"ub8 Contractors @C (civil) and company # contractor @C ( civil) shall inspect each
member prior to pouring of concrete.
"tructural member is released by @C and consultant.
Concrete pouring schedule submitted to bachting plant.

$.6 Concrete Placement;

Sta#e 2;
Concrete shall be placed at each individual pour location dependent on access and
pour configuration either byF
o &irect discharge
o Crane and skip
o Concrete pump
o Chute
The e%act method # procedure for placing concrete shall be decided depending
accessibility of structural member on site.
:ll necessary laboratory tools for fresh concrete !uality testing shall be available on
site prior to pouring of concrete ( cube moulds # cylinder mould, slump cone, thermometer
etc.) :nd third party laboratory technician is available at site or Concrete site station
( checking temperature, slump air content and fresh concrete density and samples taken as
per specifications ). Then transit mi%er $i%er released to specified Concrete location.
)lace the approved mi% concrete into layers 104 mm per layer ma%imum using one
of the above methods.
)reparation forms, reinforcement, joints and mi%ing conveying.
Concrete shall not be dropped from a height e%ceeding 7.B meters.
(%pansion # Contraction joints shall be provided as per FC drawings.
f the air temperature is less than 54 deg C concrete shall be placed within C4
minutes of the introduction of the mi%ing water to the cement and aggregates, or cement to
aggregates. f the air temperature is greater than 54 deg C mi%ing time shall be reduced and
concrete placed within ;4 minutes e%cept when a suitable set retarding mi%ture is used and
slump re!uirements can be met. The ma%imum time between batching and placing shall not
be e%ceed 7/4 minutes in all cases.
"pecific measures taken for minimum dimension of any casting is .B4 merters or
more.
-here .icker is used it shall be at least 24 mm high and carefully constructed.
Concrete in high temperature (:C standard 540.7 for hot weather concrete shall be
complied with.
The minimum concrete cover maintained as detailed in specification.
o 20mm for all concrete poured against soil.
o 04mm for all foundation concrete poured against forms.
o 14mm for all other concrete e%posed to soil but poured against forms.
o 14mm for all e%terior concrete.
o 14mm to principle reinforcement of interior beams and columns.
o 50mm for interior slabs and walls.
o 04mm for columns, beams and walls and other e%posed member of $aritime
"tructures.
1. Concrete Compaction;
Sta#e +;

Full compaction of the concrete shall be achieved throughout the entire depth of the
layer using mechanical vibrators.
<ibration of concrete shall be thoroughly worked against the formwork and around
the reinforcement> successive layers shall be thoroughly bonded together during vibration.
(nsure ,einforcement or form is not disturbed.
Compaction of concrete shall be carried out by mechanical or electrical vibrators to
e%pel all air bubbles formed during the mi%ing and casting.
mmersion vibrators shall be withdrawn slowly to prevent the formation of voids.
Care shall be taken to avoid over vibration which could cause segregation, surface
laitance or leakage through formwork.